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Grill Barrel

From "Trade School"
episode DTRS-103

Figure A

In this segment, student Conor Tracy begins his first challenge by crafting the barrel of an enormous barbecue grill (figure A). For this project, he uses a MIG welder to join the metal components. A MIG welder is fast and efficient, and can be used on a variety of metals ....

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Basic Tools:

MIG welder
Plasma cutter
Oxyacetylene torch
Square metal tubing
Disc grinder
Sheet metal break
Tape measure
Bevel T
Combination square
Steel Square
Squaring magnet
Ironworker
Clamps
Chop saw

Conor and his instructor, Jeff Klein, game-plan the process based on a drawing designed on the school computer. (figure B). The plans call for a 3' x 2" octagonal barrel shell. Conor must craft each half of the shell separately.
Starting with a piece 18-gauge sheet metal, Conor measures and marks the dimensions of the barrel in accordance with the drawing (figure C).

Figure B

Figure C

With the dimensions properly transferred, Conor cuts the sheet metal into various pieces using a plasma cutter. Combining the heat of an oxyacetylene torch and the pressure of an air compressor, a plasma cutter can blast through sheet metal quickly. Conor clamps a portion of steel tubing along the markings to guide his cuts (figure D). Then he grinds the edges with a disc grinder to remove burrs (figure E).

Figure D

Figure E

Jeff helps as Conor uses a manual break to bend two pieces of sheet metal forming the distinctive octagonal shape (figure F).
He checks each bend frequently with a sliding bevel-T until achieving the correct angles (figure G).

Figure F

Figure G

When complete, the two halves of the shell line up nicely (figure H).
To form the end caps of the shell, Conor cuts four half-octagonal shapes in the remaining sheet metal using a multi-function ironworker. An ironworker can shear, punch holes or bend thinner metals (figure I).

Figure H

Figure I

Then, on a level Platten table, which has ample clamping spaces, Conor carefully aligns each of the end caps to the half-barrels using a squaring magnet (figure J).
Once aligned, he tack-welds the end caps to the barrel halves using a wire-feed MIG welder (figure K).

Figure J

Figure K

Figure L

Tack-welding is a process in which specific spots are welded, instead of running along a seam (figure L).
Tack welds can be broken easily in case of mistakes, and also help to prevent warping metal.

Finally, Conor solid-welds along the seams using a technique called back-stepping. Back-stepping involves using short adjacent weld lengths in the opposite direction to the general progression. This reduces the risk of warping metal. He cleans up his welds with the disc grinder to complete the barrel shell (figures M and N).